Removal of Timing Belt and Sprockets on 1992 Volvo 940?

Timing Belt and Sprockets

REMOVAL & INSTALLATION

Although not necessary, replace the timing belt tensioner when replacing the belt. The tensioner can (and often does) leak hydraulic fluid, and can seize, causing the belt to break.

B230F and B230FT Engines

1. Disconnect the negative battery cable.
2. Remove the timing belt cover as described in this section.
3. Set the engine to TDC of the No. 1 cylinder.
4. To remove the tension from the belt, loosen the nut for the tensioner and press the idler roller back. The tension spring can be locked in this position by inserting the shank end of a 3mm drill through the pusher rod.
5. Remove the 6 retaining bolts and the crankshaft pulley.
6. Remove the belt, taking care not to bend it at any sharp angles. The belt should be replaced at 45,000 mile (72,500 km) intervals, if it becomes oil soaked or frayed or if it is on a vehicle that has been sitting idle for any length of time.

To install:

7. If the crankshaft, idler shaft or camshaft were disturbed while the belt was out, align each shaft with its corresponding index mark to assure proper valve timing and ignition timing, as follows:
   1. Rotate the crankshaft so the notch in the convex crankshaft gear belt guide aligns with the embossed mark on the front cover (12 o'clock position).
   2. Rotate the idler shaft so the dot on the idler shaft drive sprocket aligns with the notch on the timing belt rear cover (4 o'clock position).
   3. Rotate the camshaft so the notch in the camshaft sprocket inner belt guide aligns with the notch in the forward edge of the valve cover (12 o'clock position).
8. Install the timing belt (don't use any sharp tools) over the sprockets and then over the tensioner roller. Some new belts have yellow marks. The 2 lines on the drive belt should fit toward the crankshaft marks. The next mark should then fit toward the intermediate shaft marks, etc.
9. Loosen the tensioner nut and let the spring tension automatically take up the slack. Tighten the tensioner nut to 37 ft. lbs. (51 Nm).
10. Rotate the crankshaft one full revolution clockwise and make sure the timing marks still align.
11. Install the drive belts, radiator fan and shroud.
12. Connect the negative battery cable.

B234F Engine

See Figures 1, 2, 3, 4, 5, 6, 7 and 8

The B234F engine has 2 timing belts, one driving the camshafts and one driving the balance shafts. The camshaft belt may be removed separately; the balance shaft belt requires removal of the camshaft belt. During reassembly, the exact placement of the belts and pulleys must be observed.

1. Remove the negative battery cable.
2. Remove the timing belt covers.
3. Turn the engine to TDC, of the compression stroke, on cylinder No. 1. Make sure the marks on the cam pulleys align with the marks on the backing plate and that the marking on the belt guide plate (on the crankshaft) is opposite the TDC mark on the engine block.
4. Remove the protective cap over the timing belt tensioner locknut. Loosen the locknut, compress the tensioner, to release tension on the belts, and re-tighten the locknut, holding the tensioner in place.
5. Remove the timing belt from the camshafts. Do not crease or fold the belt. Place a mark noting the direction of the belts rotation if you are reinstalling the same belt.

The camshafts and the crankshaft must not be moved when the belt is removed.

6. Check the tensioner by spinning it counterclockwise and listening for any bearing noise within. Check also that the belt contact surface is clean and smooth. In the same fashion, check the timing belt idler pulleys. Make sure the bolts are tightened to 18.5 ft. lbs. (25 Nm).
7. If the balance shaft belt is to be removed:
   1. Remove the balance shaft belt idler pulley from the engine.
   2. Loosen the locknut on the tensioner and remove the belt. Slide the belt under the crankshaft pulley assembly. Check the tensioner and idler wheels carefully for any sign of contamination; check the ends of the shafts for any sign of oil leakage.
   3. Check the position of the balance shafts and the crankshaft after belt removal. The balance shaft markings on the pulleys should align with the markings on the backing plate and the crankshaft marking should still be aligned with the TDC mark on the engine block.
   4. When refitting the balance shaft belt, observe that the belt has colored dots on it. These marks assist in the critical placement of the belt. The yellow dot will align the right lower shaft, the blue dot will align on the crank and the other yellow dot will match to the upper left balance shaft.
   5. Carefully work the belt in under the crankshaft pulley. Make sure the blue dot is opposite the bottom (TDC) marking on the belt guide plate at the bottom of the crankshaft. Fit the belt around the left upper balance shaft pulley, making sure the yellow mark is opposite the mark on the pulley. Install the belt around the right lower balance shaft pulley and again check that the mark on the belt aligns with the mark on the pulley.
   6. Work the belt around the tensioner. Double check that all the markings are still aligned.
   7. Set the belt tension by inserting an Allen key into the adjusting hole in the tensioner. Turn the crankshaft carefully through a few degrees on either side of TDC to check that the belt has properly engaged the pulleys. Return the crank to the TDC position and set the adjusting hole just below the 3 o'clock position when tightening the adjusting bolt. Use the Allen wrench, in the adjusting hole, as a counter hold and tighten the locking bolt to 29.5 ft. lbs. (40 Nm).
   8. Check the tension of the belt. If the belt is out of specification, the belt must be readjusted.

To install:

8. Reinstall the camshaft belt by aligning the double line marking on the belt with the top marking on the belt guide plate at the top of the crankshaft. Stretch the belt around the crank pulley and place it over the tensioner and the right side idler. Place the belt on the camshaft pulleys. The single line marks on the belt should align exactly with the pulley markings. Route the belt around the oil pump drive pulley and press the belt onto the left side idler.
9. Check that all the markings align and that the engine is still positioned at TDC, of the compression stroke, for cylinder No. 1.
10. Loosen the tensioner locknut.
11. Turn the crankshaft clockwise. The cam pulleys should rotate 1 full turn until the marks again align with the marks on the backing plate.

The engine must not be rotated counterclockwise during this procedure.

12. Smoothly rotate the crankshaft further clockwise until the cam pulley markings are 1 ¹ / ₂ teeth beyond the marks on the backing plate.
13. Tighten the tensioner locknut.
14. Check the tension on the balance shaft belt; it should now be 3.8 units. If the tension is too low, adjust the tensioner clockwise. If the tension is too high, repeat Step 7g.
15. Check the belt guide for the balance shaft belt and make sure it is properly seated.
16. Install the center timing belt cover, the one that covers the tensioner, the fan shroud, fan pulley and fan.
17. Install all the drive belts and connect the battery cable.
18. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
19. Connect the negative battery cable.
20. Start the engine and allow it to run until the thermostat opens.

CAUTION

The upper and lower timing belt covers are still removed. The belt and pulleys are exposed and moving at high speed.

21. Turn the engine OFF and bring the engine to TDC, of the compression stroke, on cylinder No. 1.
22. Disconnect the negative battery cable.
23. Check the tension of the camshaft belt. Position the gauge between the right (exhaust) cam pulley and the idler. Belt tension must be 5.5 plus or minus 0.2 units. If the belt needs adjustment, remove the rubber cap over the tensioner locknut, cap is located on the timing belt cover, and loosen the locknut.
24. Insert a suitable tool between the tensioner wheel and the spring carrier pin to hold the tensioner. If the belt needs to be tightened, move the roller to adjust the tension to 6.0 units. If the belt is too tight, adjust to obtain a reading of 5.0 units on the gauge. Tighten the tensioner locknut.
25. Rotate the crankshaft so the cam pulleys move through 1 full revolution and recheck the tension on the camshaft belt. It should now be 5.5 plus or minus 0.2 units. Install the plastic plug over the tensioner bolt.
26. Final check the tension on the balance shaft belt by fitting the gauge and turning the tensioner clockwise. Only small movements are needed. After any needed readjustments, rotate the crankshaft clockwise through 1 full revolution and recheck the balance shaft belt. The tension should now be on the final specification of 4.9 plus or minus 0.2 units.
27. Install the idler pulley for the balance shaft belt.
28. Reinstall the upper and lower timing belt covers.
29. Connect the negative battery cable.
30. Start the engine and final check performance.

Fig. Fig. 1: Align the marks on the timing gears before removing the belt

Fig. Fig. 2: Remove the tensioner bolts in order to remove the timing belt

Fig. Fig. 3: Check the timing belt idler pulleys for wear or bearing noise; replace if necessary

Fig. Fig. 4: Remove the idler pulley for the balance shaft

Fig. Fig. 5: Remove the tensioner pulley to remove the balance shaft

Fig. Fig. 6: Line up the balance shafts before installing the belt

Fig. Fig. 7: Check the alignment of the balance shafts and crankshaft before tightening the tensioner

Fig. Fig. 8: Use an Allen wrench as a counterhold when tightening the tensioner pulley

2.9L 6-Cylinder Engine

See Figure 9

1. Disconnect the negative battery cable.
2. Remove the splashguard, vibration damper guard and ignition coil cover.
3. Remove the auxiliary drive belts.
4. Remove the front timing belt cover.
5. Rotate the crankshaft clockwise, until the timing marks on the camshaft pulleys/timing belt mounting plate and crankshaft pulley/oil pump housing are aligned.
6. Remove the upper timing belt cover.
7. Check the belt tensioner, as outlined in this section. Replace the tensioner, if required.
8. Remove the tensioner upper mounting bolts. Loosen the tensioner lower mounting bolt and twist the tensioner to free the plunger. Remove the lower mounting bolt and remove the tensioner.
9. Remove the timing belt.

Do not rotate the crankshaft while the timing belt is removed.

10. Check the tensioner and idler pulleys, as follows:
    1. Spin the pulleys and listen for bearing noise.
    2. Check that the pulley surfaces in contact with the belt are clean and smooth.
    3. Check the tensioner pulley arm and idler pulley mountings.
    4. Tighten the tensioner pulley arm to 30 ft. lbs. (40 Nm) and the idler pulley to 18 ft. lbs. (25 Nm).

To install:

11. Place the belt around the crankshaft pulley and right-side idler. Place the belt over the camshaft pulleys.
12. Position the belt around the water pump and press over tensioner pulley.

The timing belt lever bushing must be greased every time the belt is replaced or the tensioner pulley removed. This is necessary to help prevent seizure of the bushing, with the possible risk of incorrect belt tension. Service the bushing, using the following procedure:

1. Remove the lever mounting bolt, tensioner pulley and sleeve behind the bolt.
2. Grease the surfaces of the bushing, bolt and sleeve, using high temp grease.
3. Install the sleeve, tensioner pulley and lever mounting bolt.
4. Tighten the bolt to 30 ft. lbs. (40 Nm).

13. Insert the tensioner mounting bolts. Tighten to 18 ft. lbs. (25 Nm).
14. Remove the locking pin.
15. Install the front timing belt cover.
16. Turn the crankshaft through 2 revolutions and check that the timing marks on the crankshaft and camshaft pulleys are correctly aligned.
17. Install the ignition coil, front timing belt cover, auxiliaries drive belts, vibration damper guard and splashguard.
18. Connect the negative battery cable.
19. Start and check the engine operation.

Fig. Fig. 9: Pulley alignment marks for timing belt replacement

2.3L and 2.4L 5-Cylinder Engines

See Figures 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 and 21

1. Disconnect the negative battery cable.
2. Remove the coolant expansion tank and place it on top of the engine.
3. Remove the spark plug cover and drive belts.
4. Remove the timing belt cover.
5. Align the pulley marks with the marks on the engine mounting plate.
6. Wait five minutes after lining up marks, then install gauge 998 8500 or equivalent between the exhaust camshaft and water pump. Read the gauge using a mirror, while still installed. For 23mm belts, the tension should be 2.7-4.0 units.

If the belt tension is incorrect, the tensioner must be replaced.

7. Remove the upper tensioner bolt and loosen the lower bolt, turning the tensioner to free up the pulley.
8. Remove the lower bolt and the tensioner.
9. Remove the timing belt.

To install:

10. Turn all the pulleys listening for bearing noise. Check to see that the contact surfaces are clean and smooth.
11. Remove the tensioner pulley lever and idler pulley, lubricate the contact surfaces and bearing with grease. If the tensioner pulley lever or idler is seized replace it.
12. Install the tensioner pulley lever and idler pulley and tighten to 18 ft. lbs. (25 Nm).
13. Compress the tensioner with tool 999 5456 or equivalent and insert a 0.079 in. (2.0mm) lock pin in the piston. If the tensioner leaks, has no resistance, or will not compress, replace it.
14. Install the tensioner and tighten the bolts to18 ft. lbs. (25 Nm).
15. Install the timing belt in order:
    1. Around the crankshaft sprocket.
    2. Around the right idler pulley
    3. Around the camshaft sprockets
    4. Around the water pump
    5. Onto the tensioner pulley
16. Pull the lock pin out from the tensioner and install the upper timing cover. Turn the crankshaft two complete revolutions and check to see that the timing marks on the crankshaft and camshaft pulleys are lined up.
17. Install the timing belt covers and the fuel line clips.
18. Install the accessory belts.
19. Install the vibration damper guard and the inner fenderwell.
20. Install the spark plug cover.
21. Install the coolant reservoir tank.
22. Connect the negative battery cable.

Fig. Fig. 10: Line up the camshaft pulleys with the marks on the engine mounting plate

Fig. Fig. 11: If you are not replacing the timing belt, make sure you mark the rotational direction for proper indexing upon installation

Fig. Fig. 12: To ease installation, note the belt routing before removal

Fig. Fig. 13: The tensioner as mounted on the engine block

Fig. Fig. 14: Remove the tensioner pulley from the engine

Fig. Fig. 15: Slide the timing belt off the camshaft pulleys and remove it from the engine

Fig. Fig. 16: Remove the tensioner from the engine

Fig. Fig. 17: Install the tensioner in a vise ...

Fig. Fig. 18: ... and compress the tensioner piston until ...

Fig. Fig. 19: ... the holes align ...

Fig. Fig. 20: ... then install a 2mm lock pin (or 2mm Allen wrench, as used here)

Fig. Fig. 21: Remove the tensioner from the vise, leaving the pin or Allen wrench in the piston

ADJUSTMENT

B234F Engine

See Figure 22

1. Place a tension gauge (9988500 or equivalent) between the exhaust camshaft drive pulley and tensioner.
2. Read the gauge. If the belt tension is correct, the gauge should read between 3.2 and 4.2 units.
3. If the reading is incorrect, remove the protective rubber cap in the timing belt cover. Slacken the locknut.
4. Turn the crankshaft clockwise through one revolution. Camshaft pulley markings should again coincide with the markings on the timing belt mounting plate.

Do not turn the engine counterclockwise during belt tensioning procedure.

5. Turn the engine further clockwise until the camshaft pulley markings are 1 ¹/ ₂ teeth past the markings on the timing belt mounting plate. Tighten the tensioner locknut.
6. Turn the crankshaft clockwise to complete one revolution (TDC).
7. Check that all markings coincide.
8. Recheck the belt tension.
9. If the reading is still not correct, proceed as follows:
   1. Slacken the tensioner locknut.
   2. Install the measuring gauge.
   3. Insert a screwdriver between the tensioner pulley and the end of the spring carrier pin.
   4. Re-adjust the belt to obtain the specified tension. Tighten the tensioner locknut to 37 ft. lbs. (50 Nm).
10. Install the protective rubber cap over the tensioner locknut.
11. Install the upper timing belt cover.

Fig. Fig. 22: Adjusting the timing belt-B234F engine

2.9L 6-Cylinder Engine

1. Place a tension gauge (9988500 or equivalent) between the exhaust camshaft drive pulley and water pump.
2. Read the gauge. If the belt tension is correct, the gauge should read between 3.5 and 4.6 units.
3. If the reading is incorrect, replace the tensioner.

INSPECTION

See Figures 23, 24, 25, 26, 27, 28, 29 and 30

The timing belt should be periodically inspected for wear. Removal of the timing cover is necessary to visually check the belt for signs of wear or contamination. The belt should show no signs of wear such as cracked teeth, wear on the belt face, wear on one or both sides of the belt, and there should be no foreign materials on the belt or between the teeth. If there is oil, coolant, lubricant, or any other foreign material on the belt, it is a good idea to replace the belt due to the fact that rapid wear can result from this contamination. Usually sticking to the manufacturers guide for timing belt replacement interval will ensure little problems but it is still a good idea to periodically inspect your belt. If the belt breaks the engine will shut down and serious engine damage can occur. The proper manufacturer recommended timing belt replacement interval can be found in General Information & Maintenance .

Fig. Fig. 23: Check for premature parting of the belt

Fig. Fig. 24: Check if the teeth are cracked or damaged

Fig. Fig. 25: Look for noticeable cracks or wear on the belt face

Fig. Fig. 26: You may only have damage on one side of the belt; if so, the guide could be the culprit

Fig. Fig. 27: Foreign materials can get in between the teeth and cause damage

Fig. Fig. 28: Inspect the timing belt for cracks, fraying, glazing or damage of any kind

Fig. Fig. 29: Damage on only one side of the timing belt may indicate a faulty guide

Fig. Fig. 30: ALWAYS replace the timing belt at the interval specified by the manufacturer

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